In-Line Metallizer Assemblies and Part-Coating Conveyor Systems Incorporating the Same

ABSTRACT

In-line metallizer assemblies can include an external rotating actuator exchange that can be operable to exchange one or more parts between a conveyor system and a vacuum chamber, and an internal rotating actuator exchange within the vacuum chamber that can be operable to receive the one or more parts from the external rotating actuator exchange, transition the one or more parts to a sputter coater integrated with the vacuum chamber for metallizing, and return metallized one or more parts to the external rotating actuator exchange such that the external rotating actuator exchange can return the metallized one or more parts to the conveyor system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to Provisional PatentApplication No. 61/205,200 filed Jan. 16, 2009, which is herebyincorporated by reference in its entirety.

TECHNICAL FIELD

The present specification generally relates to metallizing parts and,more specifically, to assemblies for sputter coating plastic partsin-line with conveyor systems.

BACKGROUND

Plastic and glass parts are often painted and coated with differentmaterials to change their visual appearance. For instance, plastic partsmay first receive one or more basecoats of paint or primer. Basecoatscan fill in defects left over from manufacturing and handling as well asprovide a more durable and adhesive surface for subsequent coatings. Atopcoat may also be applied to protect the basecoat or to otherwisealter the appearance of the part. Both basecoats and topcoats can beapplied to parts as they travel about a conveyor line. It can also bedesirable to produce a reflective or metallic appearance by applying areflective metal coating. The metal coating can be applied between thebasecoat and the topcoat, on top of a basecoat without a topcoat, belowa topcoat without a basecoat, or in any other combination of basecoatsand/or topcoats. For example, a thin layer of metal can be depositedonto the surface of the part using an evaporation process such as thatavailable with a batch metallizer. However, batch metallizers and otherconventional assemblies can require the collecting and racking of largequantities of parts which can, in turn, create high cycle times for themetallizing process.

Accordingly, a need exists for alternative metallizer assemblies andconveyor systems for metallizing parts.

SUMMARY

In one embodiment, an in-line metallizer assembly includes an externalrotating actuator exchange operable to exchange one or more partsbetween a conveyor system and a vacuum chamber, and, an internalrotating actuator exchange within the vacuum chamber operable to receivethe one or more parts from the external rotating actuator exchange,transition the one or more parts to a sputter coater integrated with thevacuum chamber for metallizing, and return metallized one or more partsto the external rotating actuator exchange such that the externalrotating actuator exchange can return the metallized one or more partsto the conveyor.

In another embodiment, an in-line metallizer assembly includes anexternal rotating actuator exchange that includes one or more actuatingarms connected to a rotating pivot, the one or more actuating arms canbe operable to extend from and retract towards the rotating pivot, andthe rotating pivot being can be operable to rotate the external rotatingactuator exchange, an internal rotating actuator exchange that includesone or more internal actuating arms connected to an internal rotatingpivot, the one or more internal actuating arms can be operable to extendfrom and retract towards the internal rotating pivot, and the internalrotating pivot can be operable to rotate the internal rotating actuatorexchange, and a vacuum chamber that includes an integrated sputtercoater and houses the internal rotating actuator exchange.

In yet another embodiment, a part-coating conveyor system includes oneor more paint stations, an in-line metallizer assembly including anexternal rotating actuator exchange and an internal rotating actuatorexchange, the internal rotating actuator exchange being housed within avacuum chamber integrated with a sputter coater, wherein the in-linemetallizer assembly can be operable to continuously metallize aplurality of parts within the part-coating conveyor system, a trackconnecting the in-line metallizer assembly with the one or more paintstations, and one or more pallets operable to advance along the trackbetween the one or more paint stations and the in-line metallizerassembly.

These and additional features provided by the embodiments describedherein will be more fully understood in view of the following detaileddescription, in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments set forth in the drawings are illustrative and exemplaryin nature and not intended to limit the subject matter defined by theclaims. The following detailed description of the illustrativeembodiments can be understood when read in conjunction with thefollowing drawings, where like structure is indicated with likereference numerals and in which:

FIG. 1 depicts a schematic of an in-line metallizer assembly incooperation with a conveyor system according to one or more embodimentsshown and described herein;

FIG. 2 depicts a schematic of an in-line metallizer assembly incooperation with a conveyor system according to one or more embodimentsshown and described herein;

FIG. 3 depicts a schematic of another in-line metallizer assembly incooperation with a conveyor system according to one or more embodimentsshown and described herein;

FIG. 4 depicts a schematic of yet another in-line metallizer assembly incooperation with a conveyor system according to one or more embodimentsshown and described herein; and

FIG. 5 depicts a schematic of a part-coating conveyor system with anin-line metallizer assembly.

DETAILED DESCRIPTION

Embodiments described herein generally relate to in-line metallizerassemblies and part-coating conveyor systems incorporating in-linemetallizer assemblies. In-line metallizer assemblies generally comprisean external rotating actuator exchange and a vacuum chamber integratedwith a sputter coater. The external rotating actuator exchange may beoperable to exchange one or more parts from an adjacent conveyor systemwith one or more parts from the vacuum chamber. The vacuum chamber mayalso comprise an internal rotating actuator exchange operable totransition one or more parts between the external rotating actuatorexchange and the sputter coater. Thus, parts traveling along theconveyor system can be removed from the conveyor system, metallized(i.e., coated with a metal film), and returned to the conveyor systemfor further processing. The external rotating actuator exchange andinternal rotating actuator exchange can act in cooperation to allow forthe metallization of parts within the sputter coater while previouslymetallized parts are simultaneously exchanged with non-metallized partsoutside of the vacuum chamber. Such cooperation may allow for thecontinuous in-line metallization of parts along a conveyor system.Part-coating conveyor systems may also incorporate an in-line metallizerassembly such that a base coat, metal coat and top coat can beindependently applied to parts using a single conveyor system, such asan asynchronous conveyor system. Various embodiments of the in-linemetallizer assemblies and part-coating conveyor systems will bedescribed in more detail herein.

Referring now to FIGS. 1 and 2, an exemplary in-line metallizer assembly10 is depicted in cooperation with a conveyor system 50 as part of anexemplary part-coating conveyor system 100. As illustrated, and as willbe discussed more fully herein, the conveyor system 50 transports partsadjacent the in-line metallizer assembly 10. Pre-metallized parts 55 aretransported towards the in-line metallizer assembly 10 while metallizedparts 56 are transported away from the in-line metallizer assembly 10.An external rotating actuator exchange 20 will extend and receive (i.e.,pick-up) pre-metallized parts 55 from the conveyor system via itsactuating arms 22,23 and external door clasp 26. The external rotatingactuator exchange 20 will then retract and rotate to transport thepre-metallized parts 55 to a vacuum chamber 30. As seen in FIG. 2, thisrotation may also allow for the external rotating actuator exchange 20to simultaneously provide (i.e., drop-off) metallized parts 56 back tothe conveyor system 50. Referring to FIG. 1, an internal rotatingactuator exchange 35 disposed within the vacuum chamber 30 may thenreceive pre-metallized parts 55′ when extended (as illustrated) withinthe vacuum chamber 30. The internal rotating actuator exchange 35 canalso retract and rotate to transition pre-metallized parts 55′ withinthe vacuum chamber 30 to a sputter coater 40. The sputter coater canthen be activated such that parts 57 facing the metallizer 40 canundergo the metallizing process. As illustrated in FIG. 2, once theparts 56′ facing the sputter coater 40 are fully metallized, theinternal rotating actuator exchange 35 can retract and rotate totransition the metallized parts 56′ back towards the external rotatingactuator exchange 20. The internal rotating actuator exchange 35 cansimultaneously transition new pre-metallized parts 55′ within the vacuumchamber 30 to the sputter coater 40. The external rotating actuatorexchange 20 may then receive and transition the metallized parts 56 backonto the conveyor system 50 to complete the metallizer cycle for a givengroup of parts.

The conveyor system 50 may comprise any conveyor system operable tofacilitate the movement of objects (such as pallets 52, part carriers53,54 and/or one or more parts 55,56 as will become further appreciatedherein). For example, as depicted in FIGS. 1-4, the conveyor system 50may comprise one or more conveyor belts 51 that are each operable totransport a plurality of objects simultaneously. In another embodiment,the conveyor system 50 may comprise a plurality of rollers that allowfor objects to pass over the series of rollers with reduced friction. Inyet another embodiment, the conveyor system 50 may comprise a guide pathin which objects can drive along the guide path independent of oneanother. It should be appreciated that the conveyor system 50 maycomprise any alternative system, or combinations thereof, such that itfacilitates the movement of objects. In one specific embodiment, such asthat depicted in FIGS. 1-3, the conveyor system 50 may comprise aplurality of pallets 52 operable to be transported along the conveyorbelt 51. Each pallet 52 may be operable to hold a part carrier 53,54which itself may be operable to hold one or more parts 55,56. Asillustrated, part carriers carrying metallized parts 56 are identifiedas element 54. Part carriers carrying pre-metallized parts 55 areidentified as element 53. Pallets 52 may comprise any structure operableto hold one or more part carriers 53,54 and/or one or more parts 55,56.For example, each pallet may comprise any type of tray, plate, bin,basket, container, or other type of receptacle.

One or more parts 55,56 may thereby be transported via each pallet 52either directly or through a part carrier 53,54. Each pre-metallizedpart 55 may comprise any object that that can be metallized in a sputtercoater 40 of the in-line metallizer assembly 10 as will becomeappreciated herein. For example, pre-metallized parts 55 may compriseplastic parts, glass parts or any other part in which a more metallic orreflective appearance is desired. In one specific embodiment,pre-metallized parts 55 may comprise injection molded plastic parts.Pre-metallized parts 55 may independently comprise any size, shape andconfiguration that allows for them to enter the vacuum chamber 30 of thein-line metallizer assembly 10. Part carriers 53,54 may comprise anyapparatus operable to support one or more parts 55,56 throughout themetallizing process. For example, part carriers may comprise a pluralityof vertical pins in which each individual part 55,56 may be supported byan individual pin. In another embodiment, part carriers 53,54 mayalternatively or additional comprise any other support structure such assupport stands, seats, platforms or stages. In one specific embodiment,part carriers 53,54 may be operable to rotate each individual part55,56. For example where a part 55,56 on a part carrier 53,54 passes byone or more fixed spray guns (such as those that apply paint or othercoating to the part), the part carrier 53,54 may rotate the parts 55,56such that paint may be applied to all areas of the parts 55,56 by asingle gun. Such an embodiment may also allow for the metallizing of theentire part 55,56 when the part is placed in front of a sputter coater40 as will become appreciated herein.

Still referring to FIGS. 1 and 2, the pallets 52 holding one or morepart carriers 53,54 with one or more parts 55,56 can traverse along theconveyor belt 51 of the conveyor system 50 in a first conveyor direction59. The first conveyor direction 59 may be any direction adjacent to thein-line metallizer assembly 10. More specifically, the first conveyordirection 59 may be any direction adjacent the in-line metallizerassembly that allows for an external rotating actuator exchange 20 topick up part carriers 53,54 and/or individual parts 55,56 from theconveyor system 50. The first conveyor direction 59 may comprise alinear direction tangential to the in-line metallizer assembly 10 (suchas that depicted in FIG. 1), may comprise an arced direction that passesaround the in-line metallizer assembly 10, or may comprise any otherdirection or path that allows for the external rotating actuatorexchange 20 to pick up part carriers 53,54 and/or individual parts55,56. In one embodiment, the conveyor belt 51 may further be operableto traverse in a second conveyor direction opposite the first conveyordirection. Such an embodiment may allow pallets 52 to reverse along aconveyor system 50 to receive a metal coating.

The in-line metallizer assembly 10 may be disposed adjacent the conveyorsystem 50 and may generally comprise an external rotating actuatorexchange 20, a vacuum chamber 30 with an internal rotating actuatorexchange 35, and a sputter coater 40 integrated with the vacuum chamber30. The external rotating actuator exchange 20 may comprise anyapparatus operable to exchange one or more parts between the conveyorsystem 50 and the vacuum chamber 30. Specifically, the external rotatingactuator exchange 20 may comprise an external rotating pivot 21connected to a plurality of actuating arms 22,23,24. The rotating pivotmay comprise any device operable to rotate the external rotatingactuator exchange in an external rotating direction 29. The rotatingdirection 29 can comprise a clockwise direction, a counterclockwisedirection or a combination of both (such as where the external rotatingactuator exchange 20 first rotates in a clockwise direction beforeretracing its path in a counterclockwise direction). In one embodiment,the rotating pivot 21 may comprise a swivel or rod connected to arotational drive source. The rotational drive source may be operable toturn the rotating pivot 21 to facilitate the rotation of the externalrotating actuator exchange 20 in the external rotating direction 29. Therotational drive source may comprise any type of motor, engine,pneumatic apparatus and/or alternative source for power that is operableto rotate the external rotating actuator exchange 20 when the externalrotating actuator exchange 20 is supporting one or more part carriers53,54 and/or individual parts 55,56.

The plurality of actuating arms 22,23,24 connected to the rotating pivot21 may each comprise any device operable to extend from and retracttowards the rotating pivot 21. For example, as illustrated in FIGS. 1and 2, in one embodiment, two or more actuating arms 22,24 may connectand extend from one side of the rotating pivot 21. In such anembodiment, the two or more actuating arms 22,24 may comprise ascissor-type cooperation wherein the two or more actuating arms 22,24may extend and retract in length by collapsing and expanding in heightrespectively. In another embodiment, also as illustrated in FIGS. 1 and2, a single actuating arm 23 may connect to the rotating pivot 21. Insuch an embodiment, the single actuating arm 23 may comprise anoscillating arm that may retract within itself, or may comprise a rigidarm that is driven away from and in towards the rotating pivot 21 via aball screw. It should be appreciated that the actuating arms 22,23,24may comprise any other alternative or additional configuration operableto extend from and retract towards the rotating pivot 21. The actuatingarms 22,23,24 may be connected directly to the rotating pivot 21 or maybe indirectly connected to the rotating pivot 21 through additional,arms, levers and/or other supports. Furthermore, similar to the rotatingpivot 21, the extension and retraction of the actuating arms 22,23,24may be powered by a lateral drive source operable to extend and retractthe actuating arms 22,23,24 when the external rotating actuator exchange20 is supporting one or more part carriers 53,54 and/or individual parts55,56. The lateral drive force may further be operable to selectivelyextend or retract individual actuating arms 22,23,24. For example, wherethe actuating arm facing the vacuum 30 (actuator arm 23 in FIG. 1) isrequired to maintain its extension, the other actuating arms (actuatingarms 22,23 in FIG. 1) may nonetheless be independently extended andretracted to pick up or drop of part carriers 53,54 and/or individualparts 55,56 from the conveyor system 50. In addition, the lateral drivesource and the rotational drive source may comprise a single drivesource, or may comprise a plurality of drive sources wherein each drivesource can operate independent of the other.

Still referring to the external rotating actuator exchange 20 of thein-line metallizer assembly 10 illustrated in FIGS. 1 and 2, an externaldoor clasp may be connected to each of the one or more actuating arms22,23,24 distal the rotating pivot 21. For example, as seen in FIG. 1, afirst external door clasp 26 and a second external door clasp 27 may beconnected to the actuating arms 22,23,24 distal the rotating pivot 21.The first external door clasp 26 and second external door clasp 27 maycomprise any device operable to both releasably engage one or more partcarriers 53,54 (and/or individual parts 55,56) from the conveyor system50 as well as provide a temporary vacuum seal around the entry port 25of the vacuum chamber 30. As used herein “vacuum seal” refers to a sealthat allows for an enclosed area to maintain a pressure lower than thepressure outside of the enclosed area. In one embodiment, the firstexternal door clasp 26 and second external door clasp 27 may comprise adoor with robotic grips operable to open and close about the one or morepart carriers 53,54 and/or parts 55,56. In such an embodiment, therobotic grips may maintain sufficient pressure when closed to facilitatetransportation of the one or more part carriers 53,54 and/or parts55,56. In another embodiment, the first external door clasp 26 andsecond external door clasp 27 may comprise a flat plate (such asaluminum, iron or steel) with one or more pins or protrusions operableto engage receiving holes in the part carriers 53,54 and/or parts 55,56.In such an embodiment, the first external door clasp and second externaldoor clasp may enter the receiving holes about the part carriers 53,54and/or parts 55,56 when the actuating arms 22,23,24 are extended fromthe rotating pivot 21. Likewise, the first external door clasp andsecond external door clasp may exit the receiving holes about the partcarriers 53,54 and/or parts 55,56 when the actuating arms 22,23,24 areretracted towards the rotating pivot 21. The first external door clasp26 and the second external door clasp 27 may comprise the same type ofdevice, or may each comprise a unique type of device.

As discussed above, the first external door clasp 26 and second externaldoor clasp 27 can further be operable to provide a temporary vacuum sealaround the entry port 25 of the vacuum chamber 30 to maintain vacuumpressure as will become more appreciated herein. Specifically, both thefirst external door clasp 26 and second external door clasp 27 maycomprise sufficient size to encapsulate the entry port 25 of the vacuumchamber 30. In one embodiment, the first external door clasp 26 andsecond external door clasp 27 and/or the vacuum chamber walls mayfurther comprise a periphery sealant to assist in providing a vacuumseal between the vacuum chamber 30 and one of the external door clasps26,27. In one embodiment, the periphery sealant may comprise a rubberprotrusion such as an o-ring. In such an embodiment, the vacuum chamber30 and/or the first external door clasp 26 and second external doorclasp 27 may comprise a receiving well to receive the o-ring, or theo-ring may be directly disposed between the flat surfaces of the vacuumchamber walls 36 and one of the external door clasps 26,27.

The vacuum chamber 30 of the in-line metallizer assembly 10 may bedisposed adjacent the external rotating actuator exchange 10 and maycomprise any enclosure operable to maintain vacuum pressure and house aninternal rotating actuator exchange 35. As used herein “vacuum pressure”refers to any pressure internal an enclosure that is lower than thepressure external the enclosure. The vacuum chamber 30 can therefore,for example, comprise one or more vacuum pumps 34 connected to one ormore vacuum chamber walls 36. The vacuum pump(s) 34 may be able to pumpair out from the enclosure formed by the vacuum chamber walls 36 suchthat the enclosure possesses a vacuum pressure. The vacuum pressure maycomprise any pressure less than that outside of the vacuum chamber 30and sufficient to enable the metallizing of parts within the sputtercoater 40. For example, in one embodiment the vacuum pump(s) 34 may beable to lower the pressure in the sputter coater 40 to a pressure fromabout 5 ton to about 10 ton (i.e., about 6.7 millibar to about 13.3millibar) or to a pressure as low as about 0.008 ton (i.e., about 0.01millibar).

The internal rotating actuator exchange 35 may comprise any apparatusoperable to receive one or more parts from the external rotatingactuator exchange 20, transition the one or more parts to the sputtercoater 40 for metallizing, and transition the metallized one or moreparts back to the external rotating actuator exchange 35. The internalrotating actuator exchange 35 may comprise an overall structure similarto the external rotating actuator exchange. Specifically, the internalrotating actuator exchange may comprise an internal rotating pivot 31and internal actuating arms 32,32 connected (either directly orindirectly) to the internal rotating pivot 31. The internal rotatingpivot 31 may comprise any device operable to rotate the internalrotating actuator exchange 35 in an internal rotating direction 39. Theinternal rotating direction 39 can comprise a clockwise direction, acounterclockwise direction or a combination of both (such as where theinternal rotating actuator exchange 35 first rotates in a clockwisedirection before retracing its path in a counterclockwise direction). Inone embodiment, the internal rotating pivot 31 may comprise a swivel orrod connected to an internal rotational drive source. The internalrotational drive source may be operable to turn the internal rotatingpivot 31 to facilitate the rotation of the internal rotating actuatorexchange 35 in the internal rotating direction 39. The internalrotational drive source may comprise any type of motor, engine,pneumatic apparatus and/or alternative source for power that is operableto rotate the internal rotating actuator exchange 35 when the internalrotating actuator exchange 35 is supporting one or more part carriers53,54 and/or parts 55,56 as received from the external rotating actuatorexchange 20.

The internal actuating arms 32,33 connected to the internal rotatingpivot 31 may each comprise any device operable to extend from andretract towards the internal rotating pivot 31. As discussed above withreference to the actuating arms 22,23,24 of the external rotatingactuator exchange 20, single internal actuating arms 32,33 may connectto the internal rotating pivot 31 (as illustrated in FIG. 1) or multipleinternal actuating arms may connect to the internal rotating pivot 31.The internal actuating arms 32,33 may be connected directly to therotating pivot 31 or may be indirectly connected to the internalrotating pivot 31 through additional, arms, levers and/or othersupports. Furthermore, similar to the internal rotating pivot 31, theextension and retraction of the internal actuating arms 32,33 may bepowered by an internal lateral drive source operable to extend andretract the internal actuating arms 32,33 when the internal rotatingactuator exchange 35 is supporting one or more part carriers 53,54and/or parts 55,56 as received from the external rotating actuatorexchange 20. The internal lateral drive source and the internalrotational drive source may comprise a single drive source, or maycomprise a plurality of drive sources wherein each drive source canoperate independent of one another. The internal lateral drive sourcemay further be operable to provide enough force to the internalactuating arms to maintain vacuum pressure as will become furtherappreciated herein. Furthermore, the internal lateral drive force mayalso be operable to selectively extend or retract individual internalactuating arms 32,32 independent from one another.

Still referring to the internal rotating actuator exchange 35 in thevacuum chamber 30, an internal door clasp may be connected to each ofthe one or more internal actuating arms 32,33 distal the internalrotating pivot 31. For example, as illustrated in FIGS. 1-3, a firstinternal door clasp 37 and a second internal door clasp 38 may beconnected to the internal actuating arms 32,33 distal the internalrotating pivot 31. The first internal door clasp 37 and second internaldoor clasp 38 may comprise any device operable to both hold one or morepart carriers 53,54 (and/or individual parts 55,56) as received from theexternal rotating actuator exchange 20 as well as be sealed against thevacuum chamber 30 to maintain vacuum pressure within the vacuum chamber30 and/or the sputter coater 40. For example, in one embodiment, thefirst internal door clasp 37 and second internal door clasp 38 maycomprise box-like receptacles having one open side (i.e., the side thatfaces the entry port 25 or the sputter coater 40). In such an embodimentthe part carriers 53,54 and/or parts 55,56 may be placed in the firstinternal door clasp by the external door clasps 26,27 of the externalrotating actuator exchange 20. In another embodiment, the first internaldoor clasp 37 and second internal door clasp 38 may comprise one or morepins or protrusions operable to engage receiving holes in the partcarriers 53,54 and/or parts 55,56. In such an embodiment, the firstinternal door clasp 37 and second internal door clasp 38 may enter thereceiving holes about the part carriers 53,54 and/or parts 55,56 whenthe internal actuating arms 32,33 are extended from the internalrotating pivot 31. Likewise, the first internal door clasp 37 and secondinternal door clasp 38 may exit the receiving holes about the partcarriers 53,54 and/or parts 55,56 when the internal actuating arms 32,33are retracted towards the internal rotating pivot 31. In yet anotherembodiment, the external door clasps 26,27 may be operable to mate withthe internal door clasps 37,38 such that actuation of an external doorclasp 26,27 drives actuation of an internal door clasp 37,38 when mated.Such an embodiment may allow for controlled actuation of the internaldoor clasps 37,38 despite the vacuum pressure they experience. The firstinternal door clasp 37 and second internal door clasp 38 may comprisethe same type of device, or may each comprise a unique type of device.

As discussed above, the first internal door clasp 37 and second internaldoor clasp 38 can further be operable to be sealed against the vacuumchamber 30 to maintain vacuum pressure within the vacuum chamber 30and/or the sputter coater 40. Specifically, both the first internal doorclasp 37 and second internal door clasp 38 may comprise sufficient sizeto encapsulate the entry port of the vacuum chamber 30. When an internaldoor clasp 37,38 is pushed against the vacuum chamber wall 36 about theentry port 25, the vacuum pressure within the vacuum chamber 30 willpull on the internal door clasp if an external door clasp 26,27 is notcovering the exterior of the entry port 25. Thus, the force provided bythe internal actuating arms and the internal lateral drive source mustbe sufficient to withstand the force from the external pressure suchthat the vacuum chamber 30 can maintain vacuum pressure. In oneembodiment, the first internal door clasp 37 and second internal doorclasp 38 may further comprise a periphery sealant to assist in providinga vacuum seal between the vacuum chamber 30 and one of the internal doorclasps 37,38. In one embodiment, the periphery sealant may comprise arubber protrusion such as an o-ring. In such an embodiment, the vacuumchamber 30 may comprise a receiving well that the o-ring fits into, orthe o-ring may be disposed directly between the flat surfaces of thevacuum chamber 30 and one of the internal door clasps 37,38.

Still referring to FIGS. 1 and 2, a sputter coater 40 may further beintegrated with the vacuum chamber 30. The sputter coater 40 maycomprise any device operable for applying a metal coating to partswithin the vacuum chamber 30. For example, as illustrated in FIGS. 1-3the sputter coater 40 may comprise one or more cathodes 42 comprisingthe source material (and more specifically the metal) to be depositedonto the parts. When in operation, the sputtered metal 45 will form afilm about the parts 56 such that the parts 56 are metallized andpossess a more metallic or reflective finish. The sputtered metal cancomprise any material operable to be sputtered onto the surface of theparts such as pure metals, alloys or other materials. The sputter coatercan be completely disposed within the vacuum chamber 30, or, asillustrated in FIGS. 1-3, the sputter coater walls 41 of the sputtercoater 40 may abut against the vacuum chamber walls 36 of the vacuumchamber 30 such that a vacuum pressure is present in the sputter coater40 as maintained by the vacuum pump(s) 34. In one embodiment, thepressure in the sputter coater 40 may be greater than the pressure inthe vacuum chamber 30 such that a pressure gradient exists between thetwo causing air to flow from the sputter coater 40 to the vacuum chamber30. Such an embodiment may allow for any gas injected by (or otherwisepresent in) the sputter coater 40 to flow from the sputter coater 40 tothe vacuum chamber 30. Such gases may comprise argon or other inertgases (for example, when the sputter coater 40 injects argon during thesputtering process), water vapor, air or any other injected or residualgas. In another embodiment, a plurality of sputter coaters 40 may beintegrated with the vacuum chamber 30 such that a plurality of parts canbe metallized in different sputter coaters 40 simultaneously,sequentially or in any other order or combination.

The in-line metallizer will now be explained through an exemplary methodof operation. With reference to FIGS. 1 and 2, a plurality of parts(pre-metallized parts are identified as 55 and metallized parts areidentified as 56) may be carried by part carriers (part carrierscarrying pre-metallized parts 55 are identified as 53 and part carrierscarrying metallized parts 56 are identified as 54). Each part carrier 53is initially loaded onto its own pallet 52 and transported along theconveyor system 50 in the first conveyor direction 59. Once the pallet52 reaches the in-line metallizer assembly 10, one or more actuatingarms 22,24 of the external rotating actuator exchange 10 extend suchthat the part carrier 53 is received (e.g., picked up) from the pallet52 by the first door clasp 26. Once the part carrier 53 is secured bythe first external door clasp 26, the actuating arms 22,24 retract andthe rotating pivot 21 rotates the external rotating actuator exchange 20in the external rotating direction 29 such that the part carrier 53 heldby the first door clasp 26 now faces the entry port 25 of the vacuumchamber 30.

Within the vacuum chamber 30, the first internal door clasp 38 isalready against the vacuum chamber walls 36 so that the vacuum chamberdoes not experience an increase in pressure from the outside air. Theactuating arms 22,24 supporting the first external door clasp 26 areextended so that the first external door clasp 26 is pushed against thevacuum chamber walls 36 and the part carrier 53 is passed off to thefirst internal door clasp 37 of the internal rotating actuator exchange35. While the first external door clasp 26 remains against the vacuumchamber walls (to ensure vacuum pressure is maintained inside the vacuumchamber 30), the internal actuating arms 32,33 of the internal rotatingactuator exchange 35 retract so that the first internal door clasp 37(and second internal door clasp 38) can be rotated via the internalrotating pivot 31. Specifically, the first internal door clasp 37 isrotated such that the part carrier 53 is now facing the sputter coater40, and part carrier 54 carrying just metallized parts 56 faces thefirst external door clasp 26 of the external rotating actuator exchange20. The internal actuating arms 32,34 are then extended so that the partcarrier 53 with pre-metallized parts 55 is pushed towards the sputtercoater 40 for metallizing. Likewise, second internal door clasp 38 nowholding the part carrier 54 with metallized parts 56 is pushed againstthe vacuum chamber walls 36 around the entry port 25 such that it facesthe first external door clasp 26 of the external rotating actuatorexchange 20. While the parts 57 are being metallized via the sputtercoater 40, the second internal door clasp 38 remains against the vacuumchamber walls 36 while the first external door clasp 26 (of the externalrotating actuator exchange 20) receives the part carrier 54 from thesecond internal door clasp 38, retracts its actuating arms 22,23,24 withthe part carrier 54, rotates via its rotating pivot 21, extends itsactuating arms 22,23,24 and provides the now metallized parts 56 on thepart carrier 54 to a waiting pallet 52.

By possessing at least two actuating arms, each with its own externaldoor clasp, the external rotating actuator exchange 20 cansimultaneously receive one or more parts from the internal rotatingactuator exchange 35 and receive one or more parts from the conveyorsystem 50 (i.e. from a pallet 52). Likewise, the external rotatingactuator exchange 20 can also simultaneously provide one or more partsto the internal rotating actuator exchange 35 and provide one or moreparts to the conveyor system 50 (i.e., to a pallet 52).

Referring now to FIG. 3, an alternative in-line metallizer assembly 11is illustrated. Similar to FIG. 1, the in-line metallizer assembly 11 ofFIG. 2 generally comprises an external rotating actuator exchange 20, avacuum chamber 30 and a sputter coater 40. However, the in-linemetallizer assembly 11 further comprises an additional transfer exchange60 for transferring the pallets 52, part carriers 53,54 and/or parts55,56 from the conveyor system 50 to the external rotating actuatorexchange 20. More specifically, the transfer exchange 60 may comprise atransfer rotating pivot 61 and or one or more transfer actuating arms62,63. The transfer exchange 60 may thereby be configured to transportpallets 52, part carriers 53,54 and/or parts 55,56 between the conveyorand the external rotating actuator exchange. In one embodiment, thetransfer exchange 60 operates in a similar manner as the externalrotating actuator exchange (wherein the transfer actuating arms 62,63would repeatedly be retracted, rotated and extended). In anotherembodiment, the transfer exchange 60 may simply transport individualpallets 52, part carriers 53,54 and/or parts 55,56 in a linear mannerbetween the conveyor and the external rotating actuator exchange 20. Itshould be appreciated that the transfer exchange 60 may alternatively oradditionally embody any other transfer mechanism and may thereby provideadditional flexibility in the location of the remaining elements of thein-line metallizer assembly 11 with respect to the conveyor system 50.

Referring now to FIG. 4, yet another in-line metallizer assembly 12 isillustrated. Similar to FIG. 1, the in-line metallizer assembly of FIG.3 comprises a vacuum chamber 30 with an integrated sputter coater 40adjacent a conveyor 350. However, the in-line metallizer assembly 12further comprises an external rotating actuator multi-exchange 70 fortransferring multiple part carriers 53,54 and/or parts 55,56 between theconveyor 350 and the vacuum chamber 30. In such an embodiment, theconveyor 350 may be used to transfer part carriers 53,54 and/or parts55,56 as described above. However, the conveyor belt(s) 351,352 of theconveyor 350 may travel in both a first conveyor direction 353 and asecond conveyor direction 354 merged by a conveyor transition 355 (suchas a bend, corner or other mechanism for changing the direction ofpallets 52, part carriers 53,54 and/or parts 55,56). Both the firstconveyor direction 353 and the second conveyor direction 354 may passadjacent the external rotating actuator multi-exchange 70.

The external rotating actuator multi-exchange 70 may comprise anexternal rotating pivot 71 and a plurality of external actuating arms 72each having an external door clasp 76 attached thereto. The externalrotating actuator multi-exchange 70 may be operable to rotate in arotating direction 77 to transition between receiving pre-metallizedparts 55 from the conveyor 350 and providing metallized parts 56 backonto the conveyor 350. The external rotating actuator multi-exchange 70may specifically be operable to simultaneously receive a new partcarrier 53 from the conveyor 350, receive or provide a part carrier53,54 to or from the vacuum chamber 30, and provide part carriers 54 tothe conveyor 350. Such an embodiment may accommodate faster cycle timesby the sputter coater 40 by simultaneously picking up and dropping offpart carriers 53,54 on the conveyor 350 as opposed to sequentiallyproviding (i.e., dropping into the pallet 52) part carriers 54 and thenreceiving new part carriers 53.

Referring now to FIG. 5, the in-line metallizer assembly 10 (comprisingan external rotating actuator exchange 20, vacuum chamber 30 andintegrated sputter coater 40) can be utilized along a part-coatingconveyor system 1000. The part-coating conveyor system 1000 can comprisea single system operable to apply a basecoat, metallized coat andtopcoat using asynchronous pallets. Specifically, the part-coatingconveyor system 1000 can comprise a track 500, a basecoat station 600,an in-line metallizer assembly 10, a topcoat station 700 and one or moreprocess stations. Process stations can comprise any other stationoperable to assist in the application of coatings to the surface ofparts. For example, process stations can include a surface treatmentstation 550, a flash oven station 800 and/or a cure station 900. Thetrack 500 may comprise any type of conveyor system operable to transporta plurality of pallets 521. For example, the track can comprise aplurality of tracks with transitions and guides there between, a pathfor motorized pallets to travel across, or any alternative system. Inone embodiment, such as that illustrated in FIG. 5, the track 500 mayspecifically comprise a main track 510 and a supplemental track 511. Thesupplemental track 511 may combine with the main track 510 to allow fortwo possible paths to arrive at the same destination. By providing twodifferent paths, pallets may be directed down particular path based onthe stations the pallet has already visited. In another embodiment, thetrack 500 may comprise a single continuous track operable to transitionpallets sequentially from station to station. It should be appreciatedthat any other configuration may be employed to allow pallets to travelbetween stations.

The surface treatment station 550 may comprise any station to prepare ortreat the surface of a part before, between or after undergoing coatingand/or metallizing applications. For example, in one embodiment, thesurface treatment station 550 may comprise a blow off station operableto blow off unwanted debris, excess paint, or any other material thatmay inadvertently be present. In another embodiment, the surfacetreatment station 550 may additional or alternatively comprise amechanical brush or plasma applier. The basecoat station 600 and topcoatstation 700 may comprise any stations operable to apply a basecoat and atopcoat of paint to a plurality of parts. As described above, thebasecoat station 600 and topcoat station 700 can comprise one or morespray guns that are either fixed or moveable. The one or more spray gunsmay thereby apply paint to the surface of the parts as the parts travelthrough the basecoat station 600 and/or the topcoat station 700. Thebasecoat station 600 and the topcoat station 700 may comprise distinctstations, or, in the alternative, may comprise a single station operableto apply a basecoat and a topcoat independent of the other. The flashoven station 800 may comprise any station operable to help removesolvent from a recently applied paint (e.g., the basecoat or thetopcoat). In one embodiment, the flash oven station 800 may comprise aninfrared oven. In another embodiment, the flash oven station 800 maycomprise a convective oven. It should be appreciated that the flash ovenstation 800 may comprise any other type of oven either alternatively oradditionally such that it is operable to remove solvent from parts.Finally, the cure station 900 may comprise any station operable to curepaint recently applied to a part (e.g., the basecoat or the topcoat).The cure station 900 may comprise any combination of length andtemperature to enable the curing of UV paints. In one embodiment, thecure station may comprise a UV cure station where UV light is applied toassist in the curing of the paint. It should further be appreciated thatany other types of cure stations may be employed, either alternativelyor additionally, to help cure the paint applied to a part.

In one embodiment, the part-coating system 1000 can further comprise apart molder operable to create the original parts. The part molder cancomprise any machine operable to produce plastic parts, such as, forexample, an injection molding machine. In such an embodiment, the partmolder may be integrated with the track 500 such that parts producedfrom the part molder can directly travel along the track 500 to thebasecoat station 600, the metallizer assembly 10, the topcoat stationand/or any process station. Such an embodiment may allow for parts toforgo receiving basecoats by reducing the waiting time before beingmetallized or receiving a topcoat (and thereby reducing the chances thesurface of the parts are scratched or otherwise damaged).

Still referring to FIG. 5, the track 500 can further comprise pallets521 staged in asynchronous groups. Asynchronous groups 520 can comprisea single pallet 521 (such that each group is just a single pallet 521),a set number of pallets 521 (such that each asynchronous group 520comprises the same set number of pallets 521), or any independent numberof pallets 521 (such that each asynchronous group 520 can comprise anynumber of pallets 521 independent from one another). Asynchronous groupsare groups that can travel along the track 500 independent of oneanother. For example, as opposed to a “chain-on-edge conveyor” (i.e., aconveyor in which all parts are transported by a continuous chain suchthat each part starts and stops in synch), asynchronous pallets on thetrack 500 can start and stop independent of one another. In such anembodiment, the movement and direction of each asynchronous group 520 ofpallets 521 can be achieved through the use of RFID tags, scanners,flags, electrical signals, machine logic part mapping or any otheralternative method for tracking the status of parts to direct them tosubsequent stations.

In operation, one or more parts are loaded into pallets 521 on the track500 via one or more loaders 540. The one or more loaders 540 cancomprise any combination of manual or automatic loaders operable to loadand unload parts, part carriers and/or pallets onto the track 500. Thepallets 521 are arranged in asynchronous groups 520 where each pallet521 in the asynchronous group 520 holds parts that are at a common stage(such as no paint, base coat only, base coat and metallized coat or allcoats). An asynchronous group 520 of pallets 521 with newly molded parts(i.e., no paint coatings) may first be directed to the surface treatmentstation 550 to blow off unwanted debris left over from initialmanufacturing, or otherwise be treated to improve adhesion such asthrough the use of flames, corona or other type of plasma. Theasynchronous group 520 of pallets 521is then directed through thebasecoat station 600 where an initial base coat (e.g., a primer coat) isapplied. The base coat can help fill in surface defects left over frommanufacturing as well as provide durability and color. After theasynchronous group 520 of pallets 521 passes through the basecoatstation 600, it is directed to the flash oven station 800 and/or curestation 900 so that the basecoat can set. It should be noted that wherethe basecoat station 600 and topcoat station 700 are two separatestations in the same track line (as illustrated in FIG. 5), theasynchronous group 520 of pallets 521 could pass through the topcoatstation without actually stopping to receive the topcoat application.Depending on the desired treatment, the asynchronous group 520 ofpallets 521 can return to the basecoat station 600 to receive additionalbasecoats such that the parts are coated with a plurality of basecoats(such as a primer coat and a first coat of base paint). In thealternative, asynchronous group 520 of pallets 521 may independentlybypass the basecoat station 600 such as where parts are freshlymanufactured and have not acquired surface abrasions, scratches or otherdefects.

After completion and setting of the basecoat, the asynchronous group 520of pallets 521 would then be directed to the in-line metallizer assembly10. The external rotating actuator exchange 20 of the in-line metallizerassembly 10 may thereby continuously pickup the parts from the pallets521 (either individually or via part carriers) for metallizing whilealso returning the metallized parts to pallets 521. The in-linemetallizer assembly 10 can thereby alleviate the need to collect andremove large batches of parts to be metallized when employing a batchmetallizer. Once the parts of the asynchronous group 520 of pallets 521are all metallized, the asynchronous group 520 of pallets 521 isdirected to the topcoat station 700 (potentially via passing through thebasecoat station 600 without actually receiving a basecoat). Afterreceiving a topcoat from the topcoat station 700, the asynchronous group520 of pallets 521 is directed to the flash oven station 800 and curestation 900. Finally, the completed products in the asynchronous group520 of pallets 521 may be removed from the track 500 by the manual orautomatic loaders 540.

Where a particular machine or part breaks down thereby stopping part ofthe part-coating conveyor system 1000, asynchronous groups 520 ofpallets 521 with partially completed parts may continue on whereoperable. For example, if the basecoat station 600 breaks down, newasynchronous groups 520 of pallets 521 cannot receive a basecoat ofpaint. However, asynchronous groups 520 of pallets 521 that have alreadypassed through the basecoat station 600 can nonetheless continue throughthe application cycle since the entire track 500 is not stopped. Unlikechain-on-edge configurations, the asynchronous groups 520 help ensureparts that have received one or more coats of paint can be finalizedwithout excessive downtime, which in turn can decrease the number ofparts lost to quality control.

It should now be appreciated that in-line metallizer assemblies maycontinuously metallize parts off of a conveyor belt without the need forbatch loading/unloading. In-line metallizer can continuously pick upparts from a conveyor belt and swap them with recently metallized parts.The newly picked-up parts may be transferred to a vacuum chamber wherethey can be metallized and returned. While parts are being metallizedinside the vacuum chamber, a new set of pre-metallized parts is pickedup and exchanged with the most recently metallized parts. This in-linemetallizer assembly may further be combined with an asynchronouspart-coating conveyor system to efficiently apply a basecoat, metallizedcoat and topcoat to a part. The asynchronous grouping of pallets canhelp ensure partially completed pallets receive their next coats beforean undesirable amount of time passes.

It is noted that the terms “substantially” and “about” may be utilizedherein to represent the inherent degree of uncertainty that may beattributed to any quantitative comparison, value, measurement, or otherrepresentation. These terms are also utilized herein to represent thedegree by which a quantitative representation may vary from a statedreference without resulting in a change in the basic function of thesubject matter at issue.

While particular embodiments have been illustrated and described herein,it should be understood that various other changes and modifications maybe made without departing from the spirit and scope of the claimedsubject matter. Moreover, although various aspects of the claimedsubject matter have been described herein, such aspects need not beutilized in combination. It is therefore intended that the appendedclaims cover all such changes and modifications that are within thescope of the claimed subject matter.

1. An in-line metallizer assembly comprising: an external rotatingactuator exchange operable to exchange one or more parts between aconveyor system and a vacuum chamber; and an internal rotating actuatorexchange within the vacuum chamber operable to receive the one or moreparts from the external rotating actuator exchange, transition the oneor more parts to a sputter coater integrated with the vacuum chamber formetallizing, and return metallized one or more parts to the externalrotating actuator exchange such that the external rotating actuatorexchange can return the metallized one or more parts to the conveyorsystem.
 2. The in-line metallizer assembly of claim 1 wherein theexternal rotating actuator exchange is operable to simultaneouslyreceive one or more parts from the internal rotating actuator exchangeand receive one or more parts from the conveyor system.
 3. The in-linemetallizer assembly of claim 1 wherein the external rotating actuatorexchange is operable to simultaneously provide one or more parts to theinternal rotating actuator exchange and return one or more parts to theconveyor system.
 4. The in-line metallizer assembly of claim 1 whereinthe external rotating actuator exchange comprises one or more actuatingarms connected to a rotating pivot.
 5. The in-line metallizer assemblyof claim 4 wherein the one or more actuating arms are operable to extendfrom and retract towards the rotating pivot.
 6. The in-line metallizerassembly of claim 4 wherein the rotating pivot is operable to rotate theexternal rotating actuator exchange.
 7. The in-line metallizer assemblyof claim 1 wherein the internal rotating actuator exchange comprises oneor more internal actuating arms connected to an internal rotating pivot.8. The in-line metallizer assembly of claim 7 wherein the one or moreinternal actuating arms are operable to extend from and retract towardsthe internal rotating pivot.
 9. The in-line metallizer assembly of claim7 wherein the internal rotating pivot is operable to rotate the internalrotating actuator exchange.
 10. The in-line metallizer assembly of claim1 wherein the vacuum chamber maintains a vacuum pressure.
 11. An in-linemetallizer assembly comprising: an external rotating actuator exchangecomprising one or more actuating arms connected to a rotating pivot, theone or more actuating arms being operable to extend from and retracttowards the rotating pivot, and the rotating pivot being operable torotate the external rotating actuator exchange; an internal rotatingactuator exchange comprising one or more internal actuating armsconnected to an internal rotating pivot, the one or more internalactuating arms being operable to extend from and retract towards theinternal rotating pivot, and the internal rotating pivot being operableto rotate the internal rotating actuator exchange; and a vacuum chambercomprising an integrated sputter coater and housing the internalrotating actuator exchange.
 12. The in-line metallizer assembly of claim11 wherein an external door clasp is connected to each of the one ormore actuating arms distal the rotating pivot, the external door claspoperable to releasably engage a part carrier carrying a plurality ofparts.
 13. The in-line metallizer assembly of claim 12 wherein theexternal door clasp is further operable to provide a vacuum seal withthe vacuum chamber when the internal rotating actuator exchange isrotating.
 14. The in-line metallizer assembly of claim 11 wherein aninternal door clasp is connected to each of the one or more internalactuating arms distal the internal rotating pivot.
 15. The in-linemetallizer assembly of claim 14 wherein the internal door clasp isfurther operable to provide a vacuum seal with the vacuum chamber whenthe external rotating actuator exchange is rotating.
 16. A part-coatingconveyor system for the in-line metallization of parts, the part-coatingconveyor system comprising: one or more paint stations; an in-linemetallizer assembly comprising an external rotating actuator exchangeand an internal rotating actuator, the internal rotating actuatorexchange being housed within a vacuum chamber integrated with a sputtercoater, wherein the in-line metallizer assembly is operable tocontinuously metallize a plurality of parts within the part-coatingconveyor system; a track connecting the in-line metallizer assembly withthe one or more paint stations; and one or more pallets operable toadvance along the track between the one or more paint stations and thein-line metallizer assembly.
 17. The part-coating conveyor system ofclaim 16 wherein the one or more pallets are grouped as asynchronousgroups of pallets, each asynchronous group of pallets operable toindependently advance along the track between the one or more paintstations and the in-line metallizer assembly.
 18. The part-coatingconveyor system of claim 17 further comprising one or more processstations.
 19. The part-coating conveyor system of claim 18 wherein eachasynchronous group of pallets is also operable to independently advancealong the track to the one or more process stations.
 20. Thepart-coating conveyor system of claim 18 wherein the track furtherconnects to a part molder.